MODIFIED BASEBALL CAP AND CLOSURE LINER APPARATUS

Description

This application claims the benefit under 35 U.S.C. 119 (e) of U.S. provisional application Ser. No. 63/715,862, filed Nov. 4, 2024 and U.S. provisional application Ser. No. 63/871,166, filed Aug. 27, 2025.

FIELD OF THE INVENTION

The present invention relates to a modified baseball cap and an apparatus for being supported relative to the baseball cap, and more particularly the present invention relates to a liner apparatus and method of use of the liner apparatus to be supported inside a baseball cap for increasing the comfort of the baseball cap.

BACKGROUND

A typical baseball cap includes a crown worn over the top of the head of a user and a visor protruding forwardly from the front of the crown for partly shielding the eyes of the user from the sun. To ensure a proper fit of the crown about the head of the user, it is common to provide a circumferential gap in the bottom perimeter edge of the crown at the rear of the cap with an adjustable closure spanning the gap to allow a circumference of the crown to be adjusted to fit the circumference of the head of the user.

A common type of closure for a baseball cap is a snapback closure including a first strap member anchored at one side of the gap in the crown and a second strap member anchored at the other side of the gap in the crown, in which the first and second strap members are adjustably secured to one another with different amounts of overlap using studs on the first strap member that are releasably snap-fit into selected ones of sockets on the second strap member. The first and second strap members are typically formed of a hard plastic material. Baseball caps are commonly worn backwards so that the front visor protrudes rearwardly behind the head of the user; however, in this instance the hard plastic material of the snapback closure is typically pressed against the forehead of the user which can be uncomfortable for the user. In addition, the plastic material of the closure can also trap moisture against the skin of the user which can cause irritation to the skin.

Furthermore, the sides of the baseball cap are typically very pliable and devoid of structural reinforcement so as to require that baseball cap to be worn very tightly under circumferential tension if it is desired for the sides of the baseball cap to be snuggly received against the sides of the head.

SUMMARY OF THE INVENTION

According to one aspect of the invention there is provided a closure liner apparatus for a baseball cap including a crown for covering a top of a head of a user, a visor protruding from a front end of the crown, and a closure adjustably spanning a gap at a rear of the crown opposite from the visor such that a circumference of the crown about the head of the user is adjustable, in which the closure includes a first strap member defining studs thereon in a circumferentially extending row and a second strap member defining sockets thereon in a circumferentially extending row to selectively receive respective ones of the studs in the sockets, the apparatus comprising:

• • a liner member sized to be received on at least one of the first strap member and the second strap member of the baseball cap; and
  • a connector arranged to secure the liner member along an inner surface of said at least one of the first strap member and the second strap member of the baseball cap.

The use of a liner member arranged to be retained on one or both strap members enables a different liner material to be placed between the hard plastic material of a typical snapback closure and the skin of a user when the user wears a snapback type baseball cap in a backwards orientation. By sizing the liner member to be fully received on one or both strap members, the liner member can remain substantially hidden from view so as not to affect the desirable appears of the baseball cap.

The liner member may be sized to fully span each of the strap members by (i) cutting a stock material to fit the strap members, or (ii) selecting one or more liner member(s) from a kit of different sized liner members to be fitted onto the strap members. In addition to variation in length, width and perimeter shape to match the boundary shape of the strap members, the user can also select from different thickness of stock material or different thicknesses of liner members within a kit. In each instance, the sized liner member(s) selected by the user are subsequently attached to the strap members by suitable connectors such as stitching or adhesive so that the liner members are retained on the strap members of the baseball cap.

The connector preferably comprises an adhesive layer formed of adhesive material spanning one side of the liner member so as to be arranged to adhesively bond the liner member to said at least one of the first strap member and the second strap member.

In this instance, the apparatus may include a backing sheet spanning the adhesive layer, the backing sheet including a plurality of markings in a longitudinal row along the backing sheet in which each marking extends laterally across the backing sheet such that the markings serve as cutting guides to trim a length of the liner member, the markings being spaced apart from one another by a spacing corresponding to a spacing of the studs of the first strap member of the baseball cap.

The liner member may be shaped and sized to span the inner surface of the first strap member. In this instance, the connector may comprise stitching securing the liner member to the inner surface of the first strap member.

When the line member spans the first strap member, there may also be provided an auxiliary member shaped and sized to span a portion of a length of the inner surface of the second strap member of the baseball cap, the auxiliary member including a second connector arranged to secure the auxiliary member along the inner surface the second strap member.

The auxiliary member may be thicker than the liner member.

The auxiliary member may have a thickness corresponding to a combined thickness of the liner member and the first strap member upon which the liner member is supported.

The liner member may be shaped and sized to span a full length and a full width of said at least one of the first strap member and the second strap member when coupled.

When the baseball cap includes a sweatband or inner band extending circumferentially about a perimeter of the crown in which the sweatband is interrupted by the gap at the rear of the crown, the liner member having a liner thickness corresponding to a radial thickness that the sweatband protrudes relative to the first strap member.

The liner member may include a resilient layer formed of resilient material and arranged to be received between the liner member and said at least one of the first strap member and the second strap member.

The resilient material may comprise a foam material or a gel material.

The liner member may have an inner surface for abutment with the user comprising a moisture absorbent material. The moisture absorbent material preferably comprises a textile formed of natural fibres.

When the liner member is adapted to be mounted onto the first strap member, the line member may include a main portion sized to span the inner surface of the first strap member, and an end portion extending longitudinally from one end of the main portion and locating a mounting aperture therein so as to be arranged to extend over an end of the first strap member and receive one of the studs through the mounting aperture.

In a preferred embodiment, the liner member comprises: (i) a resilient layer formed of resilient material; (ii) a first adhesive layer formed of adhesive material spanning a first side of the resilient layer so as to be arranged to adhesively bond the first side of the resilient layer to said at least one of the first strap member and the second strap member; (iii) a textile layer spanning a second side of the resilient layer opposite the first adhesive layer; and (iv) a second adhesive layer formed of adhesive material between the textile layer and the second side of the resilient layer so as to bond the textile layer to the resilient layer. The textile layer may have top and bottom edge portions which are wrapped over respective top and bottom edges of the resilient layer and which are secured to the first side of the resilient layer by the first adhesive layer.

The closure liner apparatus may be provided in combination with the baseball cap, in which the crown has a domed shape and an open bottom end for receiving the head of the user partly therein, and the crown comprises a first textile material defining an exterior surface of the crown and terminating at a bottom perimeter edge surrounding the open bottom end of the crown, and in which the baseball cap further comprises an inner band comprising a second textile material extending along an interior surface of the crown in a circumferential direction adjacent to the bottom perimeter edge of the crown. In this instance, the crown may further comprise (i) a pair of side portions at laterally opposing sides of the visor in which the side portions are folded upwardly into an interior of the crown such that (a) a folded portion of the inner band is folded against itself at each side portion and (b) the first textile material of each side portion overlaps the folded portion of the inner band at the interior of the crown; and (ii) a row of stitching coupled to each side portion of the crown to retain the side portions of the crown folded upwardly into the interior of the crown.

According to a second aspect of the present invention there is provided a method of modifying a baseball cap including a crown for covering a top of a head of a user, a visor protruding from a front end of the crown, and a closure adjustably spanning a gap at a rear of the crown opposite from the visor such that a circumference of the crown about the head of the user is adjustable, in which the closure includes a first strap member defining studs thereon in a circumferentially extending row and a second strap member defining sockets thereon in a circumferentially extending row to selectively receive respective ones of the studs in the sockets, the method comprising:

• • providing a liner member shaped and sized to be fully received on an inner surface of at least one of the first strap member and the second strap member of the baseball cap; and
  • joining the liner member to said at least one of the first strap member and the second strap member such that the liner member is retained on the baseball cap.

According to a third aspect of the present invention there is provided a baseball cap for covering a top of a head of a user, the baseball cap comprising:

• • a crown having a domed shape and an open bottom end for receiving the head of the user partly therein, the crown comprising a first textile material defining an exterior surface of the crown and terminating at a bottom perimeter edge surrounding the open bottom end of the crown;
  • an inner band comprising a second textile material extending along an interior surface of the crown in a circumferential direction adjacent to the bottom perimeter edge of the crown;
  • a visor protruding from a front end of the crown;
  • a pair of side portions of the crown at laterally opposing sides of the visor being folded upwardly into an interior of the crown such that (i) a folded portion of the inner band is folded against itself at each side portion and (ii) the first textile material of each side portion overlaps the folded portion of the inner band at the interior of the crown; and
  • a row of stitching coupled to each side portion of the crown to retain the side portions of the crown folded upwardly into the interior of the crown.

In some embodiments, the baseball cap according to the present invention provided a unified system for structural support and comfort in headwear. More particularly the present invention provides a novel headwear system in which a snapback closure liner and folded and stitched side panels function independently or together to enhance structural integrity, fit, and comfort. This system addresses limitations found in conventional hats, including lack of side support, inconsistent head contact, and reduced thermal and moisture management. The snapback liner and the folded and stitched side panels can operate independently or as a unified system as follows. The snapback closure liner only enhances comfort and moisture management, particularly when made from grade 6A mulberry silk, which provides thermal regulation and superior moisture-wicking. Use of the fold and stitched side panels alone provides structural guidance and delivers a refined, tailored finish so as to enable a comfortable lower fit while minimizing pressure on the ears. The combined system maximizes both comfort and structural stability, providing a novel improvement over conventional headwear designs.

The folded and stitched side panels can be integrated into all hat styles, including those that do not require the snapback closure liner. The folded side panels reinforce the hat's structure, contributing to durability and maintaining the correct shape and positioning on the wearer's head. Even in elastically fitted hats, hats with a strapback closure, or fitted hat styles where the sweatband alone may provide comfort, the folded side panel reinforcement improves structural integrity as compared to the same hat without folded side panels.

More particularly, the folded and stitched side panels can be integrated into the hat body to prevent bowing at the sides, maintaining the hat's shape and ensuring stable positioning on the wearer's head. These panels provide structural reinforcement regardless of the closure type (snapback, strapback, elastic fit, or fitted). In each instance, the folded and stitched side panels are specifically designed to provide targeted structural reinforcement to the hat. By folding and stitching the fabric along the side panels, the panels create a controlled tension and support framework that directs the natural shape and curvature of the hat toward the central area where the snapback closure liner attaches to the plastic closure. The folded and stitched side panels create controlled tension in a longitudinal (front to back) direction along the sides of the headwear, preventing outward bowing and focusing the curvature of the hat towards the area protected by the snapback closure liner. This integrated structural guidance allows the liner to function as a stable anchoring and comfort zone, improving both fit and appearance.

This system allows consumers or manufacturers to select the configuration best suited to the hat style or wearer's preference, offering modular adaptability between (i) a snapback closure liner option, (ii) a side-stitched panels option, or (iii) both combined as an option.

BRIEF DESCRIPTION OF THE DRAWINGS

Some embodiments of the invention will now be described in conjunction with the accompanying drawings in which:

FIG. 1 is perspective view of a rear of a snapback type baseball cap modified according to the present invention and including a snapback closure supporting the closure liner apparatus according to a first embodiment of the present invention thereon;

FIG. 2 is an enlarged perspective view of the snapback closure and the closure line apparatus supported thereon according to the first embodiment of FIG. 1;

FIG. 3 is a partly sectional view along the line 3-3 in FIG. 2;

FIG. 4 an elevational view of an interior side of the apparatus supported on the snapback closure according to the first embodiment of FIG. 1;

FIG. 5 is a partly sectional view similar to FIG. 3 according to a second embodiment of the closure liner apparatus;

FIG. 6 is a partly sectional view similar to FIG. 3 according to a third embodiment of the closure liner apparatus;

FIG. 7 is a perspective view of stock material for use in forming the liner member according to the first embodiment of FIG. 1;

FIG. 8 is a partly sectional view of a portion of the liner member of FIG. 7;

FIG. 9 is a partly sectional view of stock material for use in forming the liner member according to the third embodiment of FIG. 6;

FIG. 10 is a plan view of strip of stock material on a backing sheet for use similarly to the roll of stock material in FIG. 7 or FIG. 9;

FIG. 11 is a schematic representation of different combinations of liner members on the first and second strap members which can each be thin, medium or thick in overall thickness relative to one another; and

FIG. 12 is a top view of the closure liner apparatus according to a further embodiment, shown mounted on the closure of a baseball cap;

FIG. 13 is a sectional view along the line 13-13 in FIG. 12;

FIG. 14 is a perspective view of the closure liner apparatus according to the embodiment of FIG. 12, shown prior to cutting the liner material from a roll of stock material;

FIG. 15 is a rear elevational view of a further embodiment of the closure liner apparatus shown mounted onto the first strap member of the baseball cap;

FIG. 16 is a sectional view along the line 16-16 of FIG. 15;

FIG. 17 is a rear elevational view of a minor variant of the embodiment of the closure liner apparatus of FIG. 15;

FIG. 18 is another perspective view of the modified baseball cap according to the first embodiment of FIG. 1; and

FIG. 19 is a sectional view along the line 18-18 in FIG. 18.

In the drawings like characters of reference indicate corresponding parts in the different figures.

DETAILED DESCRIPTION

Referring to the accompanying figures, there is illustrated a closure liner apparatus 10 arranged to be mounted on a modified baseball cap 12. The apparatus 10 is suited for use with a snapback type closure on the baseball cap 12 as illustrated in FIG. 1.

The snapback baseball cap 12 according to the illustrated embodiment includes (i) a crown 14 comprising a textile material defining an exterior surface of the cap 12 which is semi-spherical or domed in shape for covering the top of the head of a user and (ii) a visor 16 protruding forwardly from the front side of the crown for partly shielding the eyes of the user from overhead sun for example. The crown 14 is formed of a plurality of panels of the textile material which terminate at a bottom perimeter edge 18 surrounding an open bottom of the crown 14 that receives the head of the user therein such that the bottom perimeter edge 18 of the crown 14 extends circumferentially about the head of the user. A gap 20 is typically formed in the rear of the crown adjacent the bottom so as to interrupt the perimeter edge 18.

A sweatband 22 (or inner band) is situated adjacent to the bottom perimeter edge 18 to extend about an inner surface of the panels of textile material defining the crown 14 in which the sweatband 22 is also interrupted by the gap 20. The sweatband 22 is a strip or band of a moisture absorbent material such as a textile, typically including natural fibers such as cotton or wool and the like, extending along an interior surface of the crown in a circumferential direction adjacent to the bottom perimeter edge of the crown.

As shown in FIGS. 1, 18 and 19, the laterally opposing sides 100 of the cap 12 are modified relative to conventional baseball caps by arranging a pair of side portions 102 of the crown 14 immediately rearward of the visor to be folded upwardly and inwardly into the interior of the crown. More particularly, a lower folded portion 104 of the textile material of the inner band or sweatband 22 is folded up against itself, for example a lower width portion that is overlapped by 0.5 to 1 cm in height, so that the bottom perimeter edge 18 of the band remains spaced below the upper edge of the band in the modified configuration shown in the figures. The layer of textile material defining the exterior surface of the crown and the exterior surface of the side portions 102 that are sewn to the exterior side of the inner band 22 is also folded together with the folded portions 104 of the inner band. In this manner, the textile material of each side portion 102 of the crown overlaps the folded portion 104 of the inner band at the interior of the crown. A row of stitching 106 couples each side portion 102 of the crown through the folded portion 104 of the inner band to the remainder of the inner band 22 so as to retain the side portions 102 of the crown folded upwardly into the interior of the crown in the configuration shown in the Figures. The rows of stitching 106 do not penetrate through to the exterior surface of the crown to maintain a finished exterior appearance, however the stitching 106 can also be coupled through to the exterior of the crown if a stronger attachment of the side portions 102 is desired.

The stitching line is preferably approximately 1 centimeter from the original bottom perimeter edge 18 before folding and is sewn onto the inner sweatband so that the stitching line is invisible from the exterior. This method provides more of a flat edge finish. Alternatively, the stitching line can be sewn through to the exterior of the cap to provide a more defined edge or finish.

In the illustrated embodiment, a snapback closure 24 adjustably spans across the gap 20 in alignment with the sweatband 22 for adjusting the circumference of the sweatband and the bottom perimeter edge about the circumference of the head of the user. The closure 24 includes a first strap member 26 anchored at a first side of the gap 20 in the crown and a second strap member 28 anchored at an opposing second side of the gap 20 in the crown. Both strap members comprise a flat band of a hard plastic material which is flexible yet self-supporting in structure. Each strap member 26 and 28 is anchored at the respective side of the gap 20 by being stitched between the material forming the exterior crown 14 of the cap and the material forming the sweatband 22 at the interior of the crown. Each strap member 26 and 28 also extends longitudinally at least partway across the gap 20 such that the strap members overlap one another by varying amounts as the overall circumference of the crown is adjusted by the closure.

The first strap member 26 includes a row of studs 30 formed thereon at evenly spaced positions in the longitudinal direction of the strap member corresponding to a circumferential direction of the cap. The prescribed spacing between adjacent studs within the row may be 1 centimeter according to a preferred embodiment. The second strap member 28 includes a row of sockets 32 formed therein in which each socket extends radially fully through the strap member between interior and exterior sides of the strap member. The sockets 32 within the row are spaced apart from one another by the same prescribed spacing as the studs 30. Each stud 30 can be selectively retained in a snap fit relationship within any one of the selected sockets 32. The user selects the amount of overlap between the first and second strap members corresponding to a selected overall circumference of the cap and then aligns any studs in the first strap member that are overlapped by the second strap member with corresponding ones of the sockets in the second strap member. Once the studs are snap fit into the corresponding sockets with which they are aligned, the closure 24 retains the cap at the selected circumference.

Although various embodiments of the closure liner apparatus 10 are shown in the accompanying figures, features in common with the preferred embodiments will first be described. In each instance the apparatus 10 comprises one or more liner members, each having an associated connector for retaining the one or more liner members on the inner surface of one or both of the first strap member 26 and the second strap member 28. The liner members are sized to be fully received within the boundary edges of the strap members when mounted on the inner surfaces thereof. More particularly, in preferred embodiments, the apparatus 10 includes a primary liner member 34 mounted on the inner surface of the first strap member 26, and an auxiliary liner member 36 mounted on the inner surface of a portion of the second strap member 28 in which the connector comprises an adhesive layer 38 of adhesive material lining one side of the liner members for bonding the liner members to the inner surfaces of the corresponding strap members 26 and 28.

The primary liner member 34 is shaped and sized to fully span the inner surface of the first strap member while being fully received on the first strap member without protruding beyond the boundary edges of the first strap member. In this regard the primary liner member 34 has a width corresponding to the width of the first strap member 26 between the circumferentially extending top and bottom edges thereof while having a length corresponding to the length of the first strap member 26 in the circumferential direction. A free end of the primary liner member 34 is curved to be convex in shape with the radius of curvature matching the radius of curvature at the free end of the first strap member 26. In the first embodiment, the connector may also include stitching 40 that is stitched through the primary liner member and through the plastic material of the first strap member 26. The stitching has a pattern that closely follows the perimeter boundary of the first strap member to define top and bottom rows of stitching along the top and bottom edges of the strap member and a curved row of stitching joining between the top and bottom edges adjacent to the curved free end of the first strap member.

The primary liner member 34 is preferably formed of the same material as the sweatband or another similar moisture absorbing textile including woven materials or a looped pile material. The absorbent material defines an overall thickness of the primary liner member such that the thickness in a radial direction of the cap is approximately equal to a radial thickness that the sweatband protrudes radially inwardly relative to the inner surface of the first strap member 26. In this manner, an interior surface of the primary liner member 34 is substantially flush and continuous with the inner surface of the adjacent sweatband 22.

The auxiliary liner member 36 is shaped and sized to span an uncovered portion of the inner surface of the second strap member 28 that is not overlapped by the first strap member. In this regard, the user first selects the appropriate circumferential sizing of the cap and the corresponding coupling of the studs on the first strap member to corresponding ones of the sockets on the second strap member. Once the cap has been sized, the auxiliary liner member 36 is selected from a group of different sized auxiliary liner members or the auxiliary liner member is trimmed to fit to uncovered portion of the inner surface of the second strap member. In either instance, the installed auxiliary liner member 36 comprises a similar strip of absorbent material like the primary liner member 34 together with an adhesive layer 38 defining the connector that retains the auxiliary member on the second strap member. The sized auxiliary liner member 36 spans a full width of the second strap member between the longitudinally extending top and bottom edges thereof as well as spanning the exposed length between the end of the sweatband 22 at the second side of the gap 20 and the free end of the first strap member 26 coupled to the second strap member. The corresponding end of the auxiliary liner member 36 adjacent to the end of the first strap member has a concave edge with a radius of curvature matching the radius of curvature of the end of the first strap member so that the end of the auxiliary liner member 36 has a mating shape with the corresponding end of the primary liner member 34 which are substantially abutted with one another in the longitudinal or circumferential direction of the cap.

The thickness of the auxiliary liner member 36 may be derived from the same stock material as the primary liner member so as to be similar in thickness such that the inner surface of the auxiliary liner member 36 is also substantially flush with the corresponding inner surface of the adjacent sweatband 22. However, in preferred embodiments, the auxiliary liner member 36 is thicker than the primary liner member 34 such that the overall thickness of the auxiliary liner member 36 is approximately equal to a combined thickness of the primary liner member 34 and the thickness of the first strap member such that the auxiliary liner member 36 is substantially flush with the primary liner member 34 at the inner surfaces thereof.

The stock material for forming either of the primary liner member 34 or the auxiliary liner member 36 may be available as a single strip of material secured by adhesive to a rectangular backing sheet 42 as shown in FIG. 10 or secured as a strip onto a strip of backing sheet 44 as shown in FIGS. 7 and 9. In each instance, the backing sheet 42 or 44 includes a plurality of markings 46 formed thereon at evenly spaced apart positions in a single row so that the markings span across the width of the liner member while being semicircular in shape corresponding to the radius of curvature of the end of the first strap member and the corresponding end of the liner member. The markings 46 serve as a cutting guide so that in addition to cutting the stock material at the appropriate length corresponding to the length of the primary liner member 34 or the auxiliary liner member 36, the markings also serve as a guide to cut the end of the primary liner member with the prescribed convex shape and as a guide to cut the end of the auxiliary liner member with the prescribed concave shape. Use of stock material trimmed to size is desirable when both the primary liner member 34 and the auxiliary liner member 36 are provided as add-on accessories to an existing cap, however, stitching is the preferred connector type as a more permanent means of attaching the primary liner member 34 to the first strap member when attaching the primary liner member at a manufacturing level for example.

According to a first embodiment shown in FIGS. 1-4, 7, and 8, the liner members 34 and 36 are formed of a single absorbent layer 48 of absorbent material for example natural fibers woven as a loose pile according to FIG. 8. The primary liner member 34 can be secured by stitching and/or the adhesive layer as the connector that retains the primary liner member on the first strap member. The sized auxiliary liner member 36 is attached once the cap has been sized using an adhesive layer as the connector to retain the auxiliary liner member 36 on the second strap member.

According to a second embodiment shown in FIGS. 6 and 9, the primary and auxiliary liner members in this instance may include an additional intermediate resilient layer 50, for example a resilient foam material that is bonded to an interior surface of the absorbent layer 48. The adhesive layer 38 spans the other side of the resilient layer 50 for connecting both layers to the inner surface of the strap members. Similarly to the previous embodiment, the layers of the primary liner member 34 can instead be secured at the time of manufacture using stitching in place of or in addition to the adhesive layer.

According to a third embodiment shown in FIG. 5, the primary liner member 34 and the auxiliary liner member 36 in this instance may instead comprise a resilient pad including an outer shell 52 defining an interior chamber 54 therein filled with a gel material. The resilient gel pad can thus vary in shape to accommodate different contours when pressed against the skin of the user. The pad defining the liner member 34 or 36 in this instance uses the adhesive layer 38 for retaining the liner members on the inner surfaces of the corresponding strap members of the closure 24. The auxiliary liner member 36 in this instance may be selected from a kit of multiple different sizes of auxiliary liner members to again ensure that the auxiliary liner member is sized to fully span the uncovered portion of the inner surface of the second strap member after sizing of the cap to the user.

According to FIG. 11, each of the primary liner member 34 on the first strap member 26 and the auxiliary liner member 36 on the second strap member 28 can be selected from different thicknesses of material including thin, medium, thick, or double thick material so that the combination of thicknesses between the two liner members can be customized to the preference of the user.

Turning now to the embodiment of FIGS. 12 and 13, in this instance the apparatus 10 includes a primary liner member 34 which (i) may span only the first strap member 26 for use with a similar auxiliary liner member 36 that spans the second strap member 28 similarly to previous embodiments or (ii) may span the full length of the first strap member 26 and the second strap member 28 as shown once the strap members of the closure 24 are coupled at a selected sizing according to the user preference.

According to this embodiment, the primary liner member 34 (and the auxiliary liner member 36 if applicable) includes a core resilient layer 50, for example a resilient foam material having a thickness which is comparable to the thickness of the strap members 26 and 28. The resilient layer 50 is provided as a flat strip having a top edge 60 and a bottom edge 62 defining a height of the resilient layer that is approximately equal to the height of the first and second strap members 26 and 28. The flat strip of the resilient layer 50 also includes a first side 64 for attachment to the respective strap member of the closure 24 and an opposing second side 66 to be worn against the user.

A first adhesive layer 38 spans the first side 64 of the resilient layer 50 for bonding of the resilient layer to the respective strap member.

A second adhesive layer 68 spans the second side 66 of the resilient layer 50.

A textile layer 70 is bonded by the second adhesive layer 68 against the second side 66 of the resilient layer 50. The textile layer comprises a comfortable cloth material and/or absorbent material. In a preferred arrangement, the textile layer 70 comprises a high-quality silk material. The textile layer 70 is sized to fully span the second side of the resilient layer 50 while being greater in height than the resilient layer such that a top edge portion 72 of the textile layer 70 can wrap over the top edge 60 of the resilient layer and partly overlap an upper portion of the first adhesive layer 38 at the first side of the resilient layer. Similarly, the textile layer 70 includes a bottom edge portion 74 protruding beyond the bottom of the resilient layer so that the bottom edge portion can be wrapped around the bottom edge 62 of the resilient layer and partly overlap a lower portion of the first adhesive layer 38 at the first side of the resilient layer. A majority of the first adhesive layer 38 at the first side 64 of the resilient layer 50 remains exposed between the top and bottom edge portions 72 and 74 of the textile layer 70 to provide sufficient exposed adhesive for bonding to the corresponding strap members 26 and/or 28 of the closure 24.

The opposing edges of the textile layer, corresponding to the terminal edges 78 of the top edge portion 72 and the bottom edge portion 74 which are adhered at spaced apart locations on the first adhesive layer 38 at the first side of the core resilient layer 50, are preferably formed as a serrated edge as shown in FIG. 14. The serrated or zig-zag terminal edges 78 provide a more gradual transition from the thickness at the center of the liner member to the thickness at the edges of the liner member where there is an additional layer of textile at the first side. Once mounted on the closure of a baseball cap, the transition between the regions of different thickness is less noticeably felt by the user when using serrated terminal edges. Also, the zigzag pattern increases adhesive surface area, enhancing the bond with the plastic snapback closure.

Prior to mounting on the baseball cap, an additional backing layer 76 is mounted releasably across the exposed first adhesive layer for packaging. The primary liner member 34 of the apparatus 10 according to this embodiment is provided as an elongated strip with the backing layer secured thereon having a length corresponding to the longest configuration that the closure 24 can assume when coupling the first and second strap members 26 and 28 at the largest setting. Alternatively, the assembly of layers forming the liner member 34 can also be available on a roll from which the primary liner member 34 is cut to length as shown in FIG. 14. The user can also choose to cut more than one length of the liner member 34 so that the liner members can be stacked to increase the overall thickness of the resulting strap liner similar to the prior embodiment as shown in FIG. 6.

To fit the apparatus 10 to the baseball cap 12, the closure 24 is first sized to the head of the user by coupling the first and second strap members 26 and 28 at the appropriate configuration. The primary liner member 34 is then cut to length to span the combined length of the first and second strap members or the length of an individual first strap member 26 or second strap member 28 as desired. The backing layer is then removed and the exposed portion of the first adhesive layer 38 between the top edge portion 72 in the bottom edge portion 74 of the textile layer 70 is bonded to the inner surface of the closure so that the textile layer 74 forms the innermost layer at the closure 24 for being worn comfortably against the forehead of the wearer. The liner member 34 is aligned with the strap members so that the top and bottom edges of the liner member are substantially flush with the top and bottom edges of the strap members.

Turning now to FIGS. 15 through 17, according to further embodiments, the apparatus 10 in this instance includes a primary liner member 34 sized to fully span the first strap member 26. More particularly, the primary liner member 34 includes (i) a core resilient layer 50 of foam, (ii) a first adhesive layer 38 at a first side of the resilient layer 50 for bonding to the strap member 26, (iii) a second adhesive layer 68 at a second side of the resilient layer 50, and (iv) a textile layer 70 bonded to the second adhesive layer 68 at the second side, so as to be substantially identical to the previous embodiment. The liner member 34 differs from the previous embodiment in that the textile layer 70 include a main portion 108 that fully spans the inner surface of the first strap member, and an end portion 110 extending longitudinally from one end of the main portion so as to protrude beyond the rounded end of the first strap member 26. The end portion 110 locates a mounting aperture 112 therein and is suitably sized so that the end portion 110 can be wrapped over the end of the first strap member and overlap a portion of the exterior surface of the first strap member 26 up to the location of the first stud 30 of the first strap member where the mounting aperture 112 aligns with and can be extended overtop of the first stud 30. The end portion 110 of the textile layer may also be lined with adhesive to bond the end portion 110 to the exterior surface of the first strap member. The thickness of the textile layer 70 at the end portion 110 that overlaps a portion of the exterior surface of the first strap member 26 is sufficiently thin that it does not interfere with the conventional mounting of the second strap member 28 onto the studs 30 including the stud received within the mounting aperture as shown in FIG. 16.

In one version of the end portion 110 of the textile material shown in FIG. 15, the end portion 110 is joined with the main portion 108 so as to define a curved fold wrapped over the end of the first strap member 26 that matches the curved profile at the end of the first strap member.

Alternatively, as shown in FIG. 17, the end portion 110 may be joined with the main portion 108 so as to define a straight fold located at the outermost end of the first strap member 26.

According to the present invention, a baseball cap can be customized with an additional liner by providing a primary liner member 34 and an auxiliary liner member 36 as described above, together with mounting the primary liner member 34 on the first strap member 26 and mounting the auxiliary liner member 36 on the uncovered portion of the second strap member 28 as further described above.

Since various modifications can be made in the invention as herein above described, and many apparently widely different embodiments of same made, it is intended that all matter contained in the accompanying specification shall be interpreted as illustrative only and not in a limiting sense.